Suction filter and fuel supply device

ABSTRACT

A suction filter includes a filter element disposed in a fuel tank and filtering a stored fuel that is a fuel stored in the fuel tank by allowing the stored fuel passing the filter element into an inner space, a dividing wall element disposed to divide the inner space into a first space, into which a filtered fuel that is the fuel filtered by the filter element flows, and a second space, to which an intake port drawing in the filtered fuel is opened, and enclosing the first space together with the filter element and enclosing the second space together with the filter element, and a passage element including an inflow port opened to the second space and an outflow port to which an intake pressure is applied by the intake port and defining a flow passage through which filtered fuel flows from the inflow port toward the outflow port.

CROSS REFERENCE TO RELATED APPLICATION

This application is based on Japanese Patent Application No. 2015-173923filed on Sep. 3, 2015 and Japanese Patent Application No. 2015-240568filed on Dec. 9, 2015, the disclosures of which are incorporated hereinby reference.

TECHNICAL FIELD

The present disclosure relates to a suction filter and a fuel supplydevice including the suction filter.

BACKGROUND ART

A conventional fuel supply device that supplies fuel from a fuel tank ofa vehicle to an exterior of the fuel tank uses a fuel pump disposed inthe fuel tank to draw fuel into an intake port of the fuel pump anddischarges the fuel toward the exterior of the fuel tank. As one type ofsuch a fuel supply device, a device disclosed in Patent Literature 1 isprovided with a suction filter such that fuel is filtered within a fueltank and then drawn into an intake port of a fuel pump.

The suction filter disclosed in Patent Literature 1 includes a filterelement disposed in the fuel tank. The filter element allows passage ofstored fuel being the fuel stored in the fuel tank into an inner spaceto filter the stored fuel while forming a liquid film. The liquid filmremains while the outer surface of the filter element is in contact withthe stored fuel. Now, the outer space of the filter element of thesuction filter disclosed in Patent Literature 1 is partially coveredwith a storage member in the fuel tank. The outer surface of the filterelement can thus partially remain in contact with the fuel trappedbetween the filter element and the storage member even when the liquidsurface tilted by imbalanced storage of the stored fuel in the fuel tankat the time of turning of the vehicle or the like is separated from thefilter element. As a result, the filter element maintaining formation ofthe liquid film allows fuel to be predominantly drawn into the innerspace in which the intake port is opened, thereby preventing air frombeing drawn into the intake port.

PRIOR ART LITERATURE Patent Literature

-   Patent Literature 1: JP2012-67736A

SUMMARY OF INVENTION

According to the suction filter disclosed in Patent Literature 1, aninflow hole is formed on the storage member in order to allow fuel toflow in between the filter element and the storage member. The fuelbetween the filter element and the storage member at the time of turningof the vehicle or the like is therefore more likely to leak out throughthe inflow hole as the liquid surface is tilted. The amount of fueltrapped between the filter element and the storage member is thusdecreased and depleted in a short time as fuel intake progresses,whereby the formation of the liquid film cannot be maintained. As aresult, when the air is drawn into the inner space from the outer spaceof the filter element, a large amount of fuel remains in the inner spacewithout being drawn into the intake port. The filtered fuel remains inthe inner space because only the air is drawn into the intake port whenthe volume ratio of air in the inner space reaches a certain ratio orhigher. Such intake of air greatly changes the discharge performance ofa fuel pump and thus requires improvement.

It is an object of the present disclosure to provide a suction filterthat stabilizes the discharge performance of a fuel pump, and a fuelsupply device including the suction filter.

According to a first aspect of the present disclosure, the suctionfilter that filters a fuel in a fuel tank of a vehicle and then allowsthe fuel to be drawn into an intake port of a fuel pump includes afilter element disposed in the fuel tank and filtering a stored fuelthat is the fuel stored in the fuel tank, by allowing the stored fuelpassing the filter element into an inner space, a dividing wall elementdisposed to divide the inner space into a first space, into which afiltered fuel that is the fuel filtered by the filter element flows, anda second space, to which the intake port drawing in the filtered fuel isopened, and enclosing the first space together with the filter elementand enclosing the second space together with the filter element, and apassage element including an inflow port opened to the second space andan outflow port to which an intake pressure is applied by the intakeport, and defining a flow passage through which the filtered fuel flowsfrom the inflow port toward the outflow port.

According to a second aspect of the present disclosure, the fuel supplydevice that supplies a fuel from a fuel tank of a vehicle to an exteriorof the fuel tank includes a fuel pump to discharge the fuel drawn intoan intake port from the fuel tank to the exterior of the fuel tank, andthe suction filter according to the first aspect.

According to the first aspect and the second aspect, a liquid film isformed on the filter element disposed in the fuel tank by the passage ofthe stored fuel from the fuel tank into the inner space. A leakage ofthe stored fuel from the inner space can thus be prevented even when theliquid surface is tilted due to imbalanced storage of the stored fueland is separated from the filter element in the fuel tank at the time ofturning of the vehicle or the like.

The dividing wall element according to the first aspect and the secondaspect is disposed to divide the inner space of the filter element intothe first space into which the filtered fuel filtered by the filterelement flows and the second space in which the intake port of the fuelpump is opened. A liquid film is formed on the dividing wall element bythe passage of the filtered fuel from the first space into the secondspace. As a result, the filtered fuel can be trapped in the first spaceenclosed by the dividing wall element together with the filter elementforming the liquid film as described above.

The first aspect and the second aspect can thus be adapted such that thefiltered fuel in the first space remains in contact with the dividingwall element with the amount of the fuel trapped being secured by thefilter element, even when the liquid surface of the stored fuel istilted in the fuel tank. As a result, the liquid film remains on thedividing wall element enclosing the second space together with thefilter element. The filtered fuel can thus be drawn from the first spaceinto the second space in which the intake port is opened. Such drawingaction allows for an effective use of the filtered fuel in the firstspace to be able to prevent air from being drawn into the intake port,and is thus effective in terms of stabilizing the discharge performanceof the fuel pump.

The passage element according to the first aspect and the second aspectdefines the flow passage from the inflow port opened to the second spacetoward the outflow port to which the intake pressure is applied by theintake port. Accordingly, even when air is drawn into the second spacefrom the first space in which the filtered fuel is substantiallydepleted, the filtered fuel is introduced by the air that is a bubbleshape and is drawn and the filtered fuel flows from the outflow portthrough the flow passage into the inflow port to which the intakepressure is applied. As a result, the filtered fuel flowing into theinflow port flows through the flow passage by the action of the intakepressure and flows out to the intake port from the outflow port.Therefore, not only the filtered fuel around the intake port but alsothe filtered fuel around the inflow port separated from the intake portcan be drawn into the intake port in the second space.

Such drawing action allows for an effective use of not only the filteredfuel in the first space but also the filtered fuel in the second spaceto be able to prevent air from being drawn into the intake port, and canthus stabilize the discharge performance of the fuel pump.

BRIEF DESCRIPTION OF DRAWINGS

The above and other objects, features and advantages of the presentdisclosure will become more apparent from the following detaileddescription made with reference to the accompanying drawings. In thedrawings:

FIG. 1 is a cross-sectional view illustrating a fuel supply deviceaccording to a first embodiment;

FIG. 2 is an enlarged cross-sectional view of a suction filter accordingto the first embodiment and corresponds to a cross-sectional view takenalong line II-II of FIG. 3;

FIG. 3 is an enlarged cross-sectional view of a passage element of thesuction filter according to the first embodiment and corresponds to aview taken along an arrow III-III of FIG. 2;

FIG. 4 is a cross-sectional view illustrating the action and effect ofthe suction filter according to the first embodiment;

FIG. 5 is an enlarged cross-sectional view of a suction filter accordingto a second embodiment;

FIG. 6 is a cross-sectional view of the suction filter according to thesecond embodiment in a state different from that in FIG. 5;

FIG. 7 is a cross-sectional view illustrating the action and effect ofthe suction filter according to the second embodiment;

FIG. 8 is an enlarged cross-sectional view of a suction filter accordingto a third embodiment and corresponds to a cross-sectional view takenalong a line VIII-VIII of FIG. 9;

FIG. 9 is an enlarged cross-sectional view of a first passage element ofthe suction filter according to the third embodiment and corresponds toa cross-sectional view taken along a line IX-IX of FIG. 8;

FIG. 10 is a cross-sectional view illustrating a variation of FIG. 8;

FIG. 11 is a cross-sectional view illustrating a variation of FIG. 2;

FIG. 12 is a cross-sectional view illustrating a variation of FIG. 3;

FIG. 13 is a cross-sectional view illustrating a variation of FIG. 2;

FIG. 14 is a cross-sectional view illustrating a variation of FIG. 8;

FIG. 15 is a cross-sectional view illustrating a variation of FIG. 8;

FIG. 16 is a cross-sectional view illustrating a variation of FIG. 8;

FIG. 17 is a cross-sectional view illustrating a variation of FIG. 8;

FIG. 18 is a cross-sectional view illustrating a variation of FIG. 8;

FIG. 19 is a cross-sectional view illustrating a variation of FIG. 2;

FIG. 20 is a cross-sectional view illustrating a variation of FIG. 2;

FIG. 21 is a cross-sectional view illustrating a variation of FIG. 8;

FIG. 22 is a cross-sectional view illustrating a variation of FIG. 2;

FIG. 23 is a cross-sectional view illustrating a variation of FIG. 2;and

FIG. 24 is a cross-sectional view illustrating a variation of FIG. 2.

DESCRIPTION OF EMBODIMENTS

Embodiments of the present disclosure will be described hereafterreferring to drawings. In the embodiments, a part that corresponds to amatter described in a preceding embodiment may be assigned with the samereference numeral, and redundant explanation for the part may beomitted. When only a part of a configuration is described in anembodiment, another preceding embodiment may be applied to the otherparts of the configuration. The parts may be combined even if it is notexplicitly described that the parts can be combined. The embodiments maybe partially combined even if it is not explicitly described that theembodiments can be combined, provided there is no harm in thecombination.

First Embodiment

As illustrated in FIG. 1, a fuel supply device 1 according to a firstembodiment of the present disclosure is mounted in a fuel tank 2 of avehicle. The fuel supply device 1 supplies fuel in the fuel tank 2 to aninternal combustion engine 3 outside the fuel tank 2. The fuel tank 2equipped with the fuel supply device 1 is made of resin and formed intoa hollow shape, thereby storing fuel to be supplied to the internalcombustion engine 3. The internal combustion engine 3 receiving thesupply of fuel from the fuel supply device 1 may be a gasoline engine ora diesel engine. Note that a horizontal direction and a verticaldirection of the vehicle on a level surface substantially coincide witha horizontal direction and a vertical direction in FIG. 1, respectively.

The overall structure of the fuel supply device 1 will be describedfirst.

The fuel supply device 1 includes a flange 10, a sub tank 20, and a pumpunit 30.

The flange 10 is made of hard resin and formed into the shape of a disc.The flange 10 is attached to a top plate 2 a of the fuel tank 2. Theflange 10 closes a through hole 2 b passing through the top plate 2 a.

The flange 10 has a fuel supply pipe 11 and an electrical connector 12that are formed as one piece. The fuel supply pipe 11 communicates withthe pump unit 30 in the fuel tank 2. The fuel supply pipe 11 alsocommunicates with a fuel line 4 between the fuel supply pipe and theinternal combustion engine 3 outside the fuel tank 2. The fuel supplypipe 11 communicating in such a manner supplies fuel drawn into the fueltank 2 by a fuel pump 32 of the pump unit 30 to the internal combustionengine 3 outside the fuel tank 2. A metal terminal 12 a is buried in theelectrical connector 12. The metal terminal 12 a is electricallyconnected to the pump unit 30 in the fuel tank 2. The metal terminal 12a is also electrically connected to an external control circuit outsidethe fuel tank 2. Such electrical connection allows the external controlcircuit to control the fuel pump 32 of the pump unit 30.

The sub tank 20 is made of hard resin and formed into the shape of abottomed cylinder. The sub tank 20 is disposed in the fuel tank 2 withan opening 20 a facing upward. The sub tank 20 has a bottom 20 b placedon a bottom 2 c of the fuel tank 2. An inflow port 20 c passes throughthe sub tank 20 near the bottom 20 b of the sub tank. Such inflow portpassing through allows stored fuel, which is the fuel stored in the fueltank 2, to flow into the sub tank 20 through the inflow port 20 c.

The pump unit 30 is disposed to extend in and out of the sub tank 20 inthe fuel tank 2. The pump unit 30 is provided with a suction filter 31,the fuel pump 32, and a communicating member 33.

The suction filter 31 is formed into a flat shape as a whole. Thesuction filter 31 is accommodated in the fuel tank 2 and placed on thebottom 20 b of the sub tank 20. The suction filter 31 traps foreignmatter contained in the stored fuel by filtering the stored fuel flowinginto the sub tank 20 of the fuel tank 2.

The fuel pump 32 is an electric pump formed into a cylindrical shape asa whole. The fuel pump 32 is accommodated in the fuel tank 2 and extendsfrom above the suction filter 31 in the sub tank 20 to an exterior ofthe sub tank 20. An intake port 32 a of the fuel pump 32 communicateswith the suction filter 31. The fuel pump 32 is controlled by theexternal control circuit for operation. The fuel pump 32 in operationdraws filtered fuel, which is the fuel filtered by the suction filter 31in the sub tank 20 of the fuel tank 2, through the intake port 32 a. Thefiltered fuel drawn into the intake port 32 a is then pressurized in thefuel pump 32 and discharged from a discharge port 32 b of the fuel pump32 toward the internal combustion engine 3 outside the fuel tank 2.

The communicating member 33 is made of hard resin and formed into ahollow shape. The communicating member 33 is accommodated in the fueltank 2 and fixed to the flange 10, and extends from the periphery of thefuel pump 32 in the sub tank 20 to the exterior of the sub tank 20. Thecommunicating member 33 defines a communicating passage 33 a thatcommunicates with the discharge port 32 b and the fuel supply pipe 11.The communicating passage 33 a supplies the fuel discharged from thedischarge port 32 b by the fuel pump 32 toward the internal combustionengine 3 through the fuel supply pipe 11. A metal lead wire 33 b isburied in the communicating member 33 in order to electrically connectthe fuel pump 32 to the metal terminal 12 a.

The detailed structure of the suction filter 31 will now be described.As illustrated in FIGS. 1 and 2, the suction filter 31 includes a filterelement 310 and a dividing wall element 311 in the sub tank 20 of thefuel tank 2.

The filter element 310 is formed into the shape of a hollow bag withinthe sub tank 20 of the fuel tank 2 as illustrated in FIG. 2 such that anouter surface 310 a is exposed and an inner space 312 is enclosed withan inner surface 310 b. The filter element 310 is formed by joining theouter peripheral edges of a pair of filter sheets 310 c and 310 dtogether in a liquid-tight manner.

Here, each of the filter sheets 310 c and 310 d as a whole is made ofmaterial fulfilling a filtration function such as porous resin, a wovenfabric, a nonwoven fabric, resin mesh, metal mesh, or the like andformed into the shape of a soft or hard curved film. The roughness of amesh of each of the filter sheets 310 c and 310 d is set to be able totrap minute foreign matter with the outer diameter of 10 μm or larger,for example, as the foreign matter contained in the stored fuel flowinginto the sub tank 20 from inside the fuel tank 2, for example.

In the filter element 310, the upper filter sheet 310 d joined to theupper side of a lower filter sheet 310 c has a through hole 310 e. Theintake port 32 a of the fuel pump 32 passes through the through hole 310e from an outer space 315 of the filter element 310 toward the innerspace 312. The through hole 310 e is joined liquid-tightly to the intakeport 32 a above an opening portion 32 c of the intake port 32 a facingdownward.

The through hole formed in the aforementioned pass-through and joiningmodes allow the upper filter sheet 310 d of the filter element 310 to besupported by the fuel tank 2 via the pump unit 30 and the flange 10, asillustrated in FIGS. 1 and 2. As a result, a part of the lower filtersheet 310 c of the filter element 310 is in contact with the bottom 20 bof the sub tank 20.

The filter element 310 structured as described above exerts thefiltration function by trapping foreign matter at a passage of thestored fuel at the time of allowing the stored fuel flowing into the subtank 20 from the fuel tank 2 to pass the filter element 310 into theinner space 312. The passage of the stored fuel at this time are voidsin micropores when the filter element 310 is made of porous resin, voidsin fibers when the filter element is made of a woven fabric or anonwoven fabric, or voids in the mesh when the filter element is made ofresin mesh or metal mesh.

The stored fuel is trapped in the voids by surface tension at suchpassage, so that a liquid film covering the outer surface 310 a of thefilter element 310 is formed simultaneously with exertion of thefiltration function. That is, the filter element 310 exerts thefiltration function of the stored fuel while forming the liquid film onthe outer surface 310 a. The roughness of the mesh of the filter element310 is set such that the minimum spacing of the voids being the passageequals approximately 10 μm, for example, in order to collect the foreignmatter having the outer diameter as described above at the passage ofthe stored fuel.

In contrast to the filter element 310, the dividing wall element 311 isexposed in the inner space 312 of the filter element 310 within the subtank 20 of the fuel tank 2. The dividing wall element 311 that is adiaphragm shape is disposed to define a first space 312 a and a secondspace 312 b above and below the dividing wall element, respectively. Inthe present embodiment, most of the dividing wall element 311 except forthe outer peripheral edge thereof is accommodated in the entire innerspace 312 so that the entire inner space is divided completely.

As illustrated in FIG. 2, the dividing wall element 311 is joined to theouter peripheral edges of the filter sheets 310 c and 310 d all aroundbetween the edges so as to be stretched in the inner space 312. Thedividing wall element 311 joined as described above allows the firstspace 312 a to be enclosed with the dividing wall element and the upperfilter sheet 310 d, so that an upper surface 311 a of the dividing wallelement 311 is exposed in the first space 312 a. At the same time, thesecond space 312 b is enclosed with the dividing wall element 311 andthe lower filter sheet 310 c, so that a lower surface 311 b of thedividing wall element 311 is exposed in the second space 312 b.

The dividing wall element 311 as a whole is made of material fulfillinga filtration function such as porous resin, a woven fabric, a nonwovenfabric, resin mesh, metal mesh, or the like and formed into the shape ofa soft or hard flat film. The roughness of the mesh of the dividing wallelement 311 is set larger than or equal to the roughness of the mesh ofthe filter sheets 310 c and 310 d so as to allow foreign matter passingthrough the filter element 310 to also pass through the dividing wallelement 311.

The dividing wall element 311 has a through hole 311 c. The intake port32 a of the fuel pump 32 passes through the through hole 311 c from thefirst space 312 a above the dividing wall element 311 toward the secondspace 312 b below the dividing wall element 311. The through hole 311 cis joined liquid-tightly to the intake port 32 a above the openingportion 32 c of the intake port 32 a opened to the second space 312 b.

The through hole formed in the aforementioned pass-through and joiningmodes allow the dividing wall element 311 to be supported by the fueltank 2 via the pump unit 30 and the flange 10, as illustrated in FIGS. 1and 2. As a result, most of the dividing wall element 311 except for theouter peripheral edge thereof is separated from the upper filter sheet310 d therebelow to secure a predetermined volume for the first space312 a between the dividing wall element 311 and the filter element 310.At the same time, most of the dividing wall element 311 except for theouter peripheral edge thereof is separated from the lower filter sheet310 c thereabove to secure a predetermined volume for the second space312 b between the dividing wall element 311 and the filter element 310.In the present embodiment, the volume secured for the second space 312 bis smaller than the volume secured for the first space 312 a.

With the volumes secured as described above, the intake pressure by theintake port 32 a (the negative intake pressure in this case) can act onthe second space 312 b directly from the opening portion 32 c and on thefirst space 312 a indirectly through the dividing wall element 311. Theintake pressure by the intake port 32 a can also act on the outer space315 indirectly through the dividing wall element 311 and the upperfilter sheet 310 d or indirectly through the lower filter sheet 310 c.The opening portion 32 c of the intake port 32 a is disposed in an upperhalf in the second space 312 b and separated from the lower filter sheet310 c thereabove to be less likely to adsorb the lower filter sheet 310c even under the action of the intake pressure.

The dividing wall element 311 structured as described above allows thefiltered fuel being filtered by the upper filter sheet 310 d of thefilter element 310 and flowing into the first space 312 a to passthrough the dividing wall element and flow into the second space 312 bin which the intake port 32 a is opened. The passage of the filteredfuel at this time are voids in micropores when the dividing wall element311 is made of porous resin, voids in fibers when the dividing wallelement is made of a woven fabric or a nonwoven fabric, or voids in themesh when the dividing wall element is made of resin mesh or metal mesh.

The filtered fuel is trapped in the voids by surface tension at thepassage and defines a liquid film covering the upper surface 311 a ofthe dividing wall element 311. The roughness of the mesh of the dividingwall element 311 is set such that the minimum spacing of the voids beingthe passage equals approximately 10 μm to 100 μm, for example, in orderto allow the aforementioned foreign matter to pass through the passageof the filtered fuel. The filtered fuel filtered by the lower filtersheet 310 c of the filter element 310 can directly flow into the secondspace 312 b without passing through the dividing wall element 311.

As illustrated in FIGS. 1 to 3, the suction filter 31 includes a passageelement 313 and a holding element 316 in combination with the filterelement 310 and the dividing wall element 311 in the sub tank 20 of thefuel tank 2.

As illustrated in FIGS. 2 and 3, the passage element 313 is made of hardresin and formed into the shape of a rectangular flat plate providedwith a plurality of cylindrical holes. In particular, in the presentembodiment, the passage element 313 is formed by joining a pair ofpassage members 313 f and 313 g on top of each other in a liquid-tightmanner.

The passage element 313 is disposed in a position extending in thehorizontal direction from the periphery of the intake port 32 a in thesecond space 312 b. In the present embodiment, the passage element 313is entirely accommodated in the second space 312 b. As illustrated inFIGS. 1 and 2, the passage element 313 is held in the inner space 312 ofthe filter element 310 by the holding element 316 attached to the intakeport 32 a. Here, the holding element 316 is made of hard resin andsubstantially formed into the shape of a rib so as to partially exposethe surfaces 311 a and 311 b, and holds the dividing wall element 311from both sides thereof in the vertical direction. The holding element316 also holds the filter sheets 310 c and 310 d of the filter element310 by protruding toward both sides in the vertical direction from aplurality of sites.

Such a mode of holding of the holding element allows the passage element313 to be supported by the fuel tank 2 via the pump unit 30 and theflange 10. As a result, the passage element 313 is separated from thedividing wall element 311 therebelow and from the lower filter sheet 310c of the filter element 310 thereabove.

As illustrated in FIGS. 2 and 3, the passage element 313 has an equalnumber of a plurality of inflow ports 313 a, a plurality of outflowports 313 b, and a plurality of flow passages 313 c. Specifically, theinflow ports 313 a are opened on a separated side surface 313 d of thepassage element 313. The separated side surface is positioned in thesecond space 312 b separated from the opening portion 32 c of the intakeport 32 a in the horizontal direction. The filtered fuel can flow fromthe second space 312 b into the inflow ports 313 a that are opened onthe separated side surface 313 d in the second space 312 b.

The outflow ports 313 b are opened on a peripheral side surface 313 e ofthe passage element 313. The peripheral side surface is positioned inthe second space 312 b around the opening portion 32 c on the sideopposite to the side of the separated side surface 313 d in thehorizontal direction. In particular, in the present embodiment, theoutflow ports 313 b are provided on the peripheral side surface 313 ebelow the opening portion 32 c and on the outer peripheral side of theopening portion 32 c relative to an inner peripheral surface 32 dthereof. The intake pressure by the intake port 32 a can act through theopening portion 32 c on the outflow ports 313 b that are opened on theperipheral side surface 313 e in the second space 312 b.

The flow passages 313 c extend straight in the horizontal direction andsubstantially parallel to one another between the separated side surface313 d and the peripheral side surface 313 e of the passage element 313.Each of the flow passages 313 c communicates with the correspondinginflow port 313 a and outflow port 313 b therebetween. The filtered fuelcan flow through each flow passage 313 c communicating in theaforementioned manner from the corresponding inflow port 313 a towardthe corresponding outflow port 313 b.

The action and effect of the first embodiment described so far will bedescribed below.

In the first embodiment, a liquid film is formed on the filter element310 disposed in the fuel tank 2 by the passage of the stored fuel fromthe fuel tank 2 into the inner space 312. A leakage of the stored fuelfrom the inner space 312 can thus be prevented even when the liquidsurface is tilted due to imbalanced storage of the stored fuel asillustrated in FIG. 4 and is separated from the filter sheets 310 c and310 d of the filter element 310 in the sub tank 20 of the fuel tank 2 atthe time of turning of the vehicle or the like.

The dividing wall element 311 according to the first embodiment isdisposed to divide the inner space 312 into the first space 312 a intowhich the filtered fuel filtered by the filter element 310 flows and thesecond space 312 b in which the intake port 32 a of the fuel pump 32 isopened. A liquid film is formed on the dividing wall element 311 by thepassage of the filtered fuel from the first space 312 a into the secondspace 312 b. As a result, the filtered fuel can be trapped asillustrated in FIG. 4 in the first space 312 a enclosed by the dividingwall element 311 together with the filter element 310 forming the liquidfilm as described above.

The first embodiment can thus be adapted such that the filtered fuel inthe first space 312 a remains in contact with the dividing wall element311 as illustrated in FIG. 4 with the amount of the fuel trapped beingsecured by the filter element 310, even when the liquid surface of thestored fuel is tilted in the sub tank 20. As a result, the liquid filmremains on the dividing wall element 311 enclosing the second space 312b together with the filter element 310. The filtered fuel can thus bedrawn from the first space 312 a into the second space 312 b in whichthe intake port 32 a is opened. Such drawing action allows for aneffective use of the filtered fuel in the first space 312 a to be ableto prevent air from being drawn into the intake port 32 a, and is thuseffective in terms of stabilizing the discharge performance of the fuelpump 32.

As illustrated in FIG. 4, the passage element 313 according to the firstembodiment defines the flow passage 313 c from the inflow port 313 aopened to the second space 312 b toward the outflow port 313 b to whichthe intake pressure is applied by the intake port 32 a. Accordingly,even when air is drawn into the second space 312 b from the first space312 a in which the filtered fuel is substantially depleted, the filteredfuel is introduced by the air that is a bubble shape and is drawn andthe filtered fuel flows from the outflow port 313 b through the flowpassage 313 c into the inflow port 313 a to which the intake pressure isapplied. As a result, the filtered fuel flowing into the inflow port 313a flows through the flow passage 313 c by the action of the intakepressure and flows out to the intake port 32 a from the outflow port 313b. Therefore, not only the filtered fuel around the intake port 32 a butalso the filtered fuel around the inflow port 313 a separated from theintake port 32 a can be drawn into the intake port 32 a in the secondspace 312 b.

Such drawing action allows for an effective use of not only the filteredfuel in the first space 312 a but also the filtered fuel in the secondspace 312 b to be able to prevent air from being drawn into the intakeport 32 a, and can thus stabilize the discharge performance of the fuelpump 32. The discharge performance of the fuel pump 32 is stabilized inthe first embodiment in which the fuel discharged from the fuel pump 32is supplied to the internal combustion engine 3 outside the fuel tank 2,so that the vehicle can ensure drivability and acceleration performanceas well as avoid running out of gas and engine stall.

According to the first embodiment, the intake pressure by the intakeport 32 a acts more easily on the outflow port 313 b positioned aroundthe opening portion 32 c of the intake port 32 a that is opened to thesecond space 312 b. Thus, even when the air is drawn into the secondspace 312 b from the first space 312 a, the intake pressure acting onthe inflow port 313 a from the outflow port 313 b is secured large to beable to surely draw the filtered fuel to be introduced by the air intothe intake port 32 a. Such drawing action can improve the level ofeffective use of the filtered fuel and thus stability of the dischargeperformance of the fuel pump 32. Moreover, with the outflow port 313 bpositioned around the opening portion 32 c of the intake port 32 a, thedesign of the fuel pump 32 such as the shape of the intake port 32 aneed not be changed.

According to the first embodiment, the intake pressure by the intakeport 32 a acts from the outflow port 313 b on the inflow port 313 athrough the flow passage 313 c, the inflow port 313 a being disposed inthe second space 312 b separated from the intake port 32 a in thehorizontal direction. Therefore, even the filtered fuel around theinflow port 313 a separated from the intake port 32 a in the horizontaldirection can surely be drawn into the intake port 32 a in the secondspace 312 b. Such drawing action can improve the level of effective useof the filtered fuel and thus stability of the discharge performance ofthe fuel pump 32.

In the first embodiment, the volume of the second space 312 b is smallerthan the volume of the first space 312 a. Accordingly, when the air isdrawn into the second space 312 b from the first space 312 a, the amountof filtered fuel remaining in the second space 312 b without being drawninto the intake port 32 a can be reduced. The amount of filtered fuelremaining can be reduced as the volume of the second space 312 b issmaller because, when the volume ratio of air occupying the second space312 b reaches a predetermined ratio or higher, only the air issubstantially drawn into the intake port 32 a with the filtered fuelremaining in the second space 312 b. The first embodiment can thusimprove the effect of effectively using the filtered fuel in the secondspace 312 b and thus stability of the discharge performance of the fuelpump 32.

According to the first embodiment, the dividing wall element 311 that isa diaphragm shape is disposed to define the first space 312 a and thesecond space 312 b above and below the dividing wall element,respectively. The liquid film thus remains on the dividing wall element311 in the sub tank 20 until the liquid surface drops by the reductionin the stored fuel and reaches the second space 312 b, so that thefiltered fuel can be stored in the second space 312 b. As a result, thestability of the discharge performance of the fuel pump 32 can beimproved by preventing air from being drawn into the intake port 32 auntil the filtered fuel in the first space 312 a is substantiallydepleted.

In the first embodiment, the roughness of the mesh of the dividing wallelement 311 through which the filtered fuel passes is set larger than orequal to the roughness of the mesh of the filter element 310 throughwhich the stored fuel passes. Therefore, the dividing wall element 311structured to divide the inner space 312 of the filter element 310 andthus having a smaller surface area than the filter element 310 canprevent clogging of foreign matter allowed to pass through the filterelement 310. The roughness of the mesh that is set can thus prevent areduction in the stability of the discharge performance of the fuel pump32 caused by clogging in the dividing wall element 311.

Second Embodiment

As illustrated in FIG. 5, a second embodiment of the present disclosureis a variation of the first embodiment.

A dividing wall element 2311 according to the second embodiment is madeof material such as porous resin, a woven fabric, a nonwoven fabric,resin mesh, metal mesh, or the like and formed into the shape of adiaphragm that is soft and flexible. The dividing wall element 2311 isjoined to the outer peripheral edges of filter sheets 310 c and 310 dall around between the edges and is disposed in a corrugated, slackmanner to be able to expand or contract the second space 312 b. Exceptfor the flexibility and the slack structure, the dividing wall element2311 has substantially the same structure as the dividing wall element311 of the first embodiment. In the second embodiment, a holding element2316 for holding the dividing wall element 2311 from therebelow is madeof hard resin, substantially formed into the shape of a cylinder, andattached to the intake port 32 a.

The following is the principle of expanding and contracting the secondspace 312 b by the dividing wall element 2311 structured as describedabove. As illustrated in FIGS. 5 and 6, the inner space 312 is filledwith filtered fuel in the sub tank 20 while stored fuel is in contactwith at least the lower filter sheet 310 c of the filter element 310. Atthis time, the dividing wall element 2311 is separated from the passageelement 313 to maintain the volume of the second space 312 b in anexpanded state. Note that the volume of the second space 312 b at thistime may be smaller or larger than or equal to the volume of the firstspace 312 a.

On the other hand, when a liquid surface of the stored fuel is tilted inthe sub tank 20 as illustrated in FIG. 7, the filtered fuel in the firstspace 312 a can possibly be substantially depleted according to theintake action from the intake port 32 a. The dividing wall element 2311at this time sags little by little toward the passage element 313according to the intake action from the intake port 32 a, therebygradually reducing the volume of the second space 312 b. Note that thevolume of the second space 312 b at this time is smaller than the volumeof the first space 312 a as a result of the gradual reduction.

According to the second embodiment, the dividing wall element 2311 thatis flexible and disposed in the slack manner can expand or contract thesecond space 312 b. Therefore, when the filtered fuel in the first space312 a is substantially depleted in response to the intake action fromthe intake port 32 a, the second space 312 b contracts by the amountcorresponding to the filtered fuel drawn from the second space 312 b. Itis thus possible to delay the intake of air into the second space 312 bfrom the first space 312 a through the dividing wall element 2311 orfrom the outer space 315 through the lower filter sheet 310 c of thefilter element 310. When the air is drawn into the second space 312 bfrom the first space 312 a, the function of the passage element 313allows the filtered fuel stored away from the intake port 32 a to bedrawn into the intake port 32 a in the second space 312 b. The level ofeffective use of the filtered fuel in the second space 312 b can thus beincreased to be able to improve stability of the discharge performanceof the fuel pump 32.

Third Embodiment

As illustrated in FIG. 8, a third embodiment of the present disclosureis a variation of the first embodiment. A suction filter 3031 accordingto the third embodiment includes a first passage element 3314 and asecond passage element 313 in combination with the filter element 310, adividing wall element 3311, and a holding element 3316 in the sub tank20. The structure of the second passage element 313 is substantially thesame as the structure of the passage element 313 of the firstembodiment. Note that in the third embodiment, the inflow port 313 a,the outflow port 313 b, and a flow passage 313 c of the second passageelement 313 are referred to as a second inflow port 313 a, a secondoutflow port 313 b, and a second flow passage 313 c, respectively. Thedividing wall element 3311 has substantially the same structure as thedividing wall element 311 of the first embodiment except that a throughhole 3311 d through which the first passage element 3314 passes isprovided.

As illustrated in FIGS. 8 and 9, the first passage element 3314 is madeof hard resin and substantially formed into the shape of a trapezoidalflat plate provided with one rectangular hole. In particular, in thethird embodiment, the first passage element 3314 is formed by fittingand joining a pair of passage members 3314 f and 3314 g together in aliquid-tight manner. The first passage element 3314 is disposed in aposition extending along the vertical direction from the intake port 32a. The first passage element 3314 passes through the through hole 3311 dfrom the second space 312 b below the dividing wall element 3311 towardthe first space 312 a above the dividing wall element 311. The firstpassage element 3314 is joined to the through hole 3311 d in aliquid-tight manner. The first passage element 3314 is held by theholding element 3316 attached to the intake port 32 a. Here, the passagemember 3314 f provided with a substantially rib-like portion of thefirst passage element 3314 and the holding element 3316 made of hardresin together fulfill substantially the same function as that of theholding element 316 of the first embodiment.

Such modes of joining and holding allow the first passage element 3314to be supported by the fuel tank 2 via the pump unit 30 and the flange10, as is the case with the second passage element 313. As a result, thefirst passage element 3314 is separated from the lower filter sheet 310c of the filter element 310 thereabove.

The first passage element 3314 has one first inflow port 3314 a, onefirst outflow port 3314 b, and one first flow passage 3314 c.Specifically, the first inflow port 3314 a is opened on a separated topsurface 3314 d of the first passage element 3314. The separated topsurface is positioned in the first space 312 a separated from theopening portion 32 c of the intake port 32 a in the horizontaldirection. In particular, in the third embodiment, the first inflow port3314 a is positioned in an upper half in the first space 312 a, to beprovided on the separated top surface 3314 d which is separated from thedividing wall element 3311 thereabove and is in contact with the upperfilter sheet 310 d. Filtered fuel can flow from the first space 312 ainto the first inflow port 3314 a that is opened on the separated topsurface 3314 d in the first space 312 a.

The first outflow port 3314 b is opened on a proximity side surface 3314e of the first passage element 3314. The proximity side surface ispositioned in the first space 312 a in proximity to the opening portion32 c on the side opposite to the side of the separated top surface 3314d in the horizontal direction. In particular, in the third embodiment,the first outflow port 3314 b is provided on the proximity side surface3314 e contiguous with the inner peripheral surface 32 d of the openingportion 32 c, to be positioned above each second outflow port 313 b. Theintake pressure by the intake port 32 a can act through the openingportion 32 c on the first outflow ports 3314 b that is opened on theproximity side surface 3314 e in the second space 312 b.

The first flow passage 3314 c extends between the separated top surface3314 d and the proximity side surface 3314 e of the first passageelement 3314 so as to be tilted upward as the passage is separated fromthe opening portion 32 c in the horizontal direction. The first flowpassage 3314 c communicates with the first inflow port 3314 a and thefirst outflow port 3314 b therebetween. The filtered fuel can flowthrough the first flow passage 3314 c communicating in such a mannerfrom the first inflow port 3314 a toward the first outflow port 3314 b.

As described above, the first passage element 3314 according to thethird embodiment defines the first flow passage 3314 c from the firstinflow port 3314 a opened to the first space 312 a toward the firstoutflow port 3314 b exposed to the action of the intake pressure by theintake port 32 a. The first inflow port 3314 a is thus exposed to theaction of the intake pressure as well from the first outflow port 3314 bthrough the first flow passage 3314 c. The action of the intake pressurecauses air to flow into the first inflow port 3314 a even when areduction in stored fuel (such as running out of gas) or imbalancedstorage of the stored fuel in the sub tank 20 causes the air to flowinto and be trapped in the first space 312 a enclosed by the elements310 and 3311 forming the liquid film. As a result, the air flowing intothe first inflow port 3314 a flows through the first flow passage 3314 cby the action of the intake pressure and flows out to the intake port 32a from the first outflow port 3314 b. The trapped air not readilypassing through the dividing wall element 3311, on which the liquid filmis formed, from the first space 312 a is temporarily drawn into theintake port 32 a so that the first space 312 a can have the volumecapable of trapping the filtered fuel back again.

According to the function of the first passage element 3314, the levelof effective use of the filtered fuel can be increased both in the firstspace 312 a and the second space 312 b together with the function of thesecond passage element 313 similar to that of the first embodiment. Thestability of the discharge performance of the fuel pump 32 can thus beimproved.

According to the third embodiment, air having a smaller specific gravitythan the filtered fuel tends to accumulate in the upper half in thefirst space 312 a where the first inflow port 3314 a is positioned.Thus, when the trapped air in the upper half in the first space 312 a istemporarily drawn into the intake port 32 a, the first space 312 a ismore likely to have the volume capable of trapping the filtered fuelback again. As a result, the effective use of the filtered fuel in thefirst space 312 a can particularly be enhanced to be able to contributeto the improvement in the stability of the discharge performance of thefuel pump.

Other Embodiment

The present disclosure is not limited to the embodiments mentionedabove, and can be changed and modified to various embodiments which arealso within the spirit and scope of the present disclosure.

Specifically, a first variation related to the first to thirdembodiments may be provided with at least one outflow port 313 b on theperipheral side surface 313 e that is separated from the opening portion32 c thereabove and is contiguous with an inner peripheral surface 1032f of the intake port 32 a, as illustrated in FIG. 10.

FIG. 10 illustrates the first variation of the third embodiment.

A second variation related to the first to third embodiments may beprovided with at least one outflow port 313 b on the peripheral sidesurface 313 e positioned directly below the opening portion 32 c, asillustrated in FIG. 11. FIG. 11 illustrates the second variation of thefirst embodiment.

A third variation related to the first to third embodiments may form oneinflow port 313 a, one outflow port 313 b, and one flow passage 313 c inthe passage element 313 provided with a cylindrical hole and having theshape of a pipe, as illustrated in FIG. 12. In the third variation ofthe first embodiment illustrated in FIG. 12, the outflow port 313 b isprovided on the peripheral side surface 313 e positioned directly belowthe opening portion 32 c, in accordance with the second variation.

A fourth variation related to the first to third embodiments may beprovided with the passage element 313 on each of both sides of theintake port 32 a while sandwiching the intake port in the horizontaldirection, as illustrated in FIG. 13. FIG. 13 illustrates the fourthvariation of the first embodiment. A fifth variation related to thethird embodiment may be provided with the first passage element 3314 oneach of both sides of the intake port 32 a while sandwiching the intakeport in the horizontal direction, in accordance with the fourthvariation.

A sixth variation related to the first to third embodiments may usedividing wall elements 311, 2311, and 3311 having no through hole 311 cand having the shape of a diaphragm to divide the inner space 312 intothe first space 312 a formed on the lower side of the inner space andthe second space 312 b formed on the upper side of the inner space 312,as illustrated in FIG. 14. The sixth variation of the third embodimentillustrated in FIG. 14 is provided with the first outflow port 3314 b onthe proximity side surface 3314 e positioned below the opening portion32 c and the second outflow port 313 b and on the outer peripheral sideof the opening portion 32 c relative to the inner peripheral surface 32d thereof. The sixth variation of the third embodiment illustrated inFIG. 14 is also provided the first flow passage 3314 c tilted downwardas the passage is separated from the opening portion 32 c along thehorizontal direction. The sixth variation of the third embodimentillustrated in FIG. 14 is further provided with the first inflow port3314 a positioned in the upper half in the first space 312 a below thedividing wall element 3311.

A seventh variation related to the third embodiment may form one firstinflow port 3314 a, one first outflow port 3314 b, and one first flowpassage 3314 c in the first passage element 3314 provided with acylindrical hole and having the shape of a pipe, as illustrated in FIG.15. An eighth variation related to the third embodiment may form aplurality of first inflow ports 3314 a, a plurality of first outflowports 3314 b, and a plurality of first flow passages 3314 c inaccordance with the first embodiment.

A ninth variation related to the third embodiment may form the firstinflow port 3314 a on the lower side in the first space 312 a asillustrated in FIG. 16. A tenth variation related to the thirdembodiment may form the first outflow port 3314 b that is separated fromthe opening portion 32 c thereabove and is opened on the innerperipheral surface 1032 f of the intake port 32 a, as illustrated inFIG. 17. An eleventh variation related to the third embodiment need notbe provided with the second passage element 313 as illustrated in FIG.18.

A twelfth variation related to the first to third embodiments maydispose the inflow port 313 a apart from the intake port 32 a therebelowin the second space 312 b. A thirteenth variation related to the firstto third embodiments may secure the volume of the second space 312 b tobe larger than or equal to the volume of the first space 312 a. Afourteenth variation related to the first to third embodiments may setthe roughness of the mesh of dividing wall elements 311, 2311, and 3311through which filtered fuel passes to be finer than the roughness of themesh of the filter element 310 through which stored fuel passes.

A fifteenth variation related to the first to third embodiments maypartially divide the inner space 312 by providing a communicating window1317 in a part of dividing wall elements 311, 2311, and 3311, asillustrated in FIG. 19. In the fifteenth variation of the firstembodiment illustrated in FIG. 19, the communicating window 1317 isdisposed in the dividing wall element 311 separated from the intake port32 a along the horizontal direction.

A sixteenth variation related to the first to third embodiments may formthe first space 312 a and the second space 312 b by dividing the innerspace 312 with dividing wall elements 311, 2311, and 3311 having theshape of a hollow, upside-down bottomed cylinder (that is, anupside-down cup shape), as illustrated in FIG. 20. In the sixteenthvariation of the first embodiment illustrated in FIG. 20, the dividingwall element 311 having the shape of the upside-down bottomed cylinderis joined to the lower filter sheet 310 c of the filter element 310. Inthe sixteenth variation of the first embodiment illustrated in FIG. 20,such a mode of joining allows the lower filter sheet 310 c of the filterelement 310 to enclose the second space 312 b together with the dividingwall element 311. At the same time, in the sixteenth variation of thefirst embodiment illustrated in FIG. 20, the upper filter sheet 310 dand the lower filter sheet 310 c of the filter element 310 enclose thefirst space 312 a together with the dividing wall element 311. In thesixteenth variation of the first embodiment illustrated in FIG. 20, thedividing wall element 311 is held by the holding element 2316 of thesecond embodiment.

A seventeenth variation related to the first to third embodiments mayadopt a structure in which the fuel supply device 1 is not provided withthe sub tank 20. An eighteenth variation related to the first to thirdembodiments may form the opening portion 32 c of the intake port 32 a ofthe fuel pump 32 to be opened not downward but in the horizontaldirection or the like in the second space 312 b.

A nineteenth variation related to the first to third embodiments maydispose the inflow port 313 a on the side of the intake port 32 a alongthe horizontal direction in the second space 312 b, as illustrated inFIG. 21. FIG. 21 illustrates the nineteenth variation of the thirdembodiment. A twentieth variation related to the third embodiment maydispose the first inflow port 3314 a on the side of the intake port 32 aalong the horizontal direction in the first space 312 a, as illustratedin FIG. 21. The twentieth variation illustrated in FIG. 21 in accordancewith the first embodiment may dispose the second inflow port 313 a inthe second space 312 b separated from the intake port 32 a along thehorizontal direction.

In a twenty-first variation related to the first to third embodiments, apart 1310 f of the filter element 310 that is hollow as a whole may bemade of material such as hard resin not fulfilling a filtration functionin place of material fulfilling the filtration function, as illustratedin FIGS. 22 and 23. FIGS. 22 and 23 illustrate the twenty-firstvariation of the first embodiment in which the part 1310 f of each offilter sheets 310 c and 310 d is made of material not fulfilling thefiltration function.

In a twenty-second variation related to the first to third embodiments,a part 1311 e of dividing wall elements 311, 2311, and 3311 having theshape of a diaphragm as a whole may be made of material such as hardresin not fulfilling a filtration function in place of materialfulfilling the filtration function, as illustrated in FIGS. 23 and 24.FIGS. 23 and 24 illustrate the twenty-second variation of the firstembodiment.

1. A suction filter that filters a fuel in a fuel tank of a vehicle andthen allows the fuel to be drawn into an intake port of a fuel pump, thesuction filter comprising: a filter element disposed in the fuel tankand filtering a stored fuel that is the fuel stored in the fuel tank, byallowing the stored fuel passing the filter element into an inner space;a dividing wall element disposed to divide the inner space into a firstspace, into which a filtered fuel that is the fuel filtered by thefilter element flows, and a second space, to which the intake portdrawing in the filtered fuel is opened, and enclosing the first spacetogether with the filter element and enclosing the second space togetherwith the filter element; and a first passage element including a firstinflow port opened to the first space at a position in an upper half inthe first space and a first outflow port to which an intake pressure isapplied by the intake port, and defining a flow passage through whichthe filtered fuel flows from the first inflow port toward the firstoutflow port; and a second passage element including a second inflowport opened to the second space and a second outflow port to which theintake pressure is applied by the intake port, and defining a flowpassage through which the filtered fuel flows from the second inflowport toward the second outflow port.
 2. The suction filter according toclaim 1, wherein the outflow port is positioned around an openingportion of the intake port, the opening portion being opened to thesecond space.
 3. The suction filter according to claim 1, wherein theinflow port is positioned in the second space separated from the intakeport in a horizontal direction.
 4. The suction filter according to claim1, wherein a volume of the second space is smaller than a volume of thefirst space.
 5. The suction filter according to claim 1, wherein thedividing wall element that is a diaphragm shape is disposed to definethe first space and the second space above and below the dividing wallelement, respectively. 6-8. (canceled)
 9. The suction filter accordingto claim 1, wherein a roughness of a mesh of the dividing wall elementthrough which the filtered fuel passes is set to be larger than or equalto the roughness of the mesh of the filter element through which thestored fuel passes.
 10. A fuel supply device that supplies a fuel froman interior of a fuel tank of a vehicle to an exterior of the fuel tank,the fuel supply device comprising: a fuel pump to discharge the fueldrawn into an intake port from the interior of the fuel tank to theexterior of the fuel tank; and the suction filter according to claim 1.